Control systems



April 30, 1957 H. D. voLLMER ET Al. 2,790,429

CONTROL SYSTEMS 5 Sheets-Sheet 1 Filed Nov. 6, 1951 INVENTORS HARDEN D. VOLLMER 'WILLIAM L. PAULISON JR.

aszwowooa AND 23m@ mul- Om April 30, 1957 D. voLLMER ET AL CONTROL.y SYSTEMS 5 sneaks-sheet 2 Filed NOV. 6, 1951 April 30, 1957 H. D. voLLMER x-:T Al. 2,790,429

CONTROL SYSTEMS Filed Nov. 6, 1951 5 Sheets-Sheet 3 April 30, 1957 H. D. VOLLMER ETAL I2,790,429

CONTROL SYSTEMS 5 Sheets-Sheet 4 med Nov. e. 1951 .llmb RR.. .SME EJ m. SMN RLO OLS Tol E.U VDA e WN... M Q1 RM O r l Am H Hm A m :Sii:

April 30, 1957 H. D. voLLMER ET Al. 2,790,429

CONTROL SYSTEMS 5 Sheets-Sheet 5 Filed NOV. 6, 1951 Y INVENTORS 45 HARDEN D. VOLLMER WILLIAM L. PAULISON JR..

CONTROL SYSTEMS Harden D. Vollmer, Richmond, Va., and William L. Paulison, Jr., Ridgewood, N. J., assgnors to Barley Meter Company, a corporation of Delaware Application November 6, 1951, Serial No. 255,038 24 Claims. (Cl. 122-479) Our invention relates broadly to the control of heat exchange apparatus `for regulating the final temperature of vapors or gases.

More specifically, the invention relates .to the control of an indirect heat exchanger located -in the path of the ow of steam generated by a vapor generator for maintaining the superheated steam leaving the unit within desired temperature limits. It will be evident that our invention may be adapted `to other arrangements of power producing or utilizing apparatus and that we have merely chosen, by way of example, to illustrate and describe certain preferred embodiments.`

A preferred form of our invention is herein exem plir'ed by a control of the rate of supply of water -to a condenser type indirect hea-t exchanger or attemperator constituting the inlet header of a superhea-ter which is supplied with steam from the separation drum of a' vapor generator. Another embodiment discloses a control of the supply of cooling water to an indirect heat exchanger located between a primary and a secondary superheater in the flow path -of steam from a separation drum of ythe vapor generator. In either embodiment the heat exchanger serves the purpose of regulating the final temperature of the steam leavingfthe unit to maintain it within desired limits.

A principal object of the invention lies in the control of the rate of water supplied to the heat exchanger, in

accordance with one or more selected variables iny thev operation of the unit, to the end that the finall temperature of the steam will be maintained within certain i limits.

Another object is toco-ntrol a heat exchanger in such a manner that the steam produced by the unit will bey with-in the desired limits of total temperatureat diEer-J ent rates of output within the controllable rangeof unit operation.

A further object is to particularly adapt a control system for start-up and stand-by operation of what may be normally considered as a continuous operation.

A further object is to control the heat exchanger re? sponsive to an indication of demand as well as responsive to an indication of one or more variable conditions of the steam.

Another object is to for controlling the supply of water to a heat exchanger, responsive to rate of unit operation as well as to correct for tendencies of the produced steam to depart from desired final temperature.

Further objects will be evident from a study of the drawings and of the description thereof, the examples being preferred embodiments of our invention.

in the drawings:

Fig. 1 is a diagrammatic View of our control system for a `heat exchanger in a system for producing confY tro'lled temperature superheated steam with a unit`hav ing a convection type superheater. v

Fig. 1A is the same as Fig. l except to'include a dift ferent index of demand.

provide method and apparatus 2,790,429 Patented Apt." 30,1957

'ice

- our invention as a control system for a heat exchanger in connection with -a vapor generator having both a primary and a secondary superheater, one of which may be a radiant type and the other a convection type.

Referring now particularly to Fig. .1, we illustrate therein in somewhat diagrammatic fashion the control of cooling water supplied to a heat exchanger or attemperator located in the flow path between the boiler separation drum and a single superheater which may, for the sake of example, bea convection type having a characteristic of generally increasing lfunction with load. We do not .believe that it is necessary to complicate the drawing by illustrating the furnace and other portions of the vapor generator whichdo not concern themselves primarily with our invention but serve in well known manner to supply heated water and steam to separation drum 1.

.The drum 1 is connected by a plurality of saturated steam connections 2 with'a superheater' inlet header 3 which takes'the form of a condenser type heat exchanger or attemperator. Leaving the header 3 are numerous superheater elements 4 which may later be joined in known manner by a header or headers from which the main unit discharge 'steam connection 100 (Fig. 1A) is taken. As diagrammatically indicated in Fig. 1 we are concerned, in the present invention, with a control of heated feed water supplied to the drum 1 by way of an economizer and the heat exchanger 3, and thus the'draw-` ingillustrates merely those portions of the vapor generating unit, supplemented by a Vcontrol system comprising our invention.

`It istcontemplated that the unit lof Fig. 1 is of a typev having a single superheater (the elements 4) and the location of such superheater relative to the furnace or to the -flow path of the. hot gasesA of c-ombustion is immaterial in the present invention but is chosen in known manner so that the necessary quantity and value of heated gases is applied to the superheater whereby, in connection with the controlled heat exchanger 3, the ultimateV temperature of the superheated steam leaving the unitV isl within the desired limits. When we speak hereafter o f the final steam temperature we are, of course, re-V and/or the amount of moisture carried along with thesteam. Thus we provide a primary or coarse control of the attemperator in accordance with the dictates of de-` mand upon the unit, but we utilize the final temperature of the superheated steam leaving the superheater elements 4 as a checkback or Vernier readjustment of the t primary control and take into account corrections for valve characteristics and :the like. The control system of our invention is in general adapted to proportion the amount of feed water going to the unit along two paths, one of which leads directly to the separation drum 1 andv the other leads to the drum 'by yway of the heat exchanger 3; AIt is 'in'thecontrol of such distributionofthe feed water supply that weare primarilyuconcerned.

Feed water is supplied tothe unit through aicc'induit 5 branching to conduits 6 and 7. In the conduit 6 is a regulating valve X and an economizer 8. Loatedin the conduit branch 7 is a regulating valve Yatter which the conduit branches to opposite ends of tl1 e,. l 1eatV exchanger 3, passing therefrom toI join the conduit 6. o n its way to the Vdrum 1. The control of `the total rate of supply of feed water to the unitv through the conduit 5 does not form a part of our present invention andv is not thereforeY illustrated'in Eigsl. `v`We ,are concerned primarily with the distribution of the watergheing fed through the conduitgas ,to whetheritis passed'directly to themdrumpil.A org-.whether a portion of the water rst goes, through theheat: exchanger .3. .t

ThevlveX; iS ils/:passed (inthe-conduit..6)x;byfan adjustable yalve 9 whiehfwillallow at4 alltimes vsutlicient passageffowater through the economizer to prevent steamingihereofgw i M Y f. i .r

Operation ofvtheyalves X,Y regulates the operation of Vthe heatlexchanger 3 in such amanner as to .produce steam leaving: thev unit within thevv desired. temperature limits. Positioning of thevvalves is accomplished automaticallythrough the agency `,of a control systemjdominated by ameasure of demand upon the unit andv by naltemperatureof the steam vleaving thetunit. ,n As an indication of, demand` or load upon the unit we showan `air ow meter 10 arranged tolvertically position the movable elementof -a pneumatic pilot valvell, thereby establishing in a pipe 12 an air loading pressurecontinually,,representative ofrate1.of air iiow through/the vapor generatoriunit. The pilot valvell is preferably of thetypedisclosed and claimed in the patent to Johnson 2,054,464. Y,

Byffair flow" `we intendV to include the rate of ow 'of the gaseous products of combustion and excess air-passing through the unit, i. e. the assembly; of vapor-generator, superheater, economizer, etc. As is well known by thoselfamiliarwith the art, air ilow has long been utilized pas an indication .of firing rate or heatfliberation and therebyan indication Vof heat. availablility for vaporizing the liquid ,and superheating the vapor. Gnthe other,l hand, the rate .of ilow ofsteam produced lunder constant conditions of temperature and pressuredsj a measureof 'heat absorption. When ai vapor-generator of the type being describedis one-of several supplying a header,;,system,f the -rate of.v steam outflow may-be` al preferableguide to -unit 4operation as-anVA indication of loador, demand. On theother hand, when such a vapor generatorsupplies a single consumer, such 'as a turbine, thedemand isrelativelyiconstant.and variations in'fi'ring or lient.absorption of the surfacesshowup as vvariations intemperature andr pressure ofthe produced steam. "In either -cas.e,.pressure is usually theindex utilized to- Ycon,- trol the ,supply ofithe elements of combustion and therebythe heat liberation, so that we ymay assumethat steam outtlow, pressure 4is maintainedsubstantially constant. In the present embodiment, :we have preferably-utilized air ow Aas an; index .of .tiring rate and heat availability. However, we may, under` certain conditions of operation, desirably `utilize steam ow asa measurable variablefi'ndicative ofdemand or loadupon the unit as a whole. Such.. a -system is shown in Fig. 1A which otherwise lis the same as-Fig. 1.

,Wehave illustrated at '13 a meter continuously responsive to the total'te'mperature Yof the steam leaving.' the unit and arranged to vertically position the movable .elen ment of a pilot valve Alll to thereby establish `in ,a 'pipe 15 an air` loading pressure kcontinuously".representing `the total temperature of the superheated steam-leaving the Theoretically `a control of V'the proportioningf the feed water -through the conduits and 7, primarily from f anidi'catin of load'or: demand'uponth unit and with achek back from iinalV steam temperature, would provide a satisfactory solution for the problem of maintaining a uniform final steam temperature. However, due to variables in the operation of such a unit, it is found that the problem is not quite this simple. Our present invention provides method and apparatus suitably taking into consideration the various extraneous effects which may be detrimental to operation.

The unit herein contemplated may be designed for continuous operation at a rate of 500,000 lb. per hr. with peak operation of l650,000 lb. per hr.of steam aty 1200 p. s. i. g. and 1000V FTT. The convection type superheater normally has an expected characteristic of an increasing function with load. Thus, even though the convection superlieating surface'is designed to produce steam at 1000 FTT at rated load, the steam temperature will be vexcessive through that range in rating between rated and peak load, while it may be below the desired value from rated vload downwardly. The unit maytherefore be designed to produce steam at 1000 FTT at a rating slightly below rated load operation which means that thev rating span of excessive temperature is greater than for the design rst discussed. Provisionis lthen made to preclude the possibility of over-run of the characteristic curve above desired nalsteam temperature by conditioning or attemperating the steam as it enters the convection superheater.

This is accomplished by a condenser type heat exchanger ofthe indirect type where some of the boiler feed'water is passed in heat exchange relation with the superheated steam leaving the separation drum on its way to the superheating surface. This provides a control of the moisture content of the steam entering the superheater by condensing part of the steam through using a part of the boiler feed water as the cooling medium, and adds nosolids to the steam. The present method, the ,manufacturer points out, isrfaster than either the gas by-pass or desuperheating methods known because it requires less surface for the same controllable 'range than the desuperheating method and the temperature'of less metal has to be changed when the steam temperature varies. As a further advantage, pointed out for the condenser. method, is that pressure loss due to the steam ilo'wing over the condenser surface is negligible, as compared to the pressure loss through or over desuperheating surface, if the amount of desuperheating surface isnot tofbe prohibitive. -Our present invention is directed to the control of the heat exchange water passed through the. condenser attemperator and specifically in proportioning` the water passed to the vapor generator unit betweenow through the economizer and flow through the condenser.

From the above discussion, one would naturally expect that, beginning the application of cooling water to the condenser yat a preselected rating, the rate of supply :of cooling water should be along an increasing character- `stic substantially similar to the expected characteristic ofthe convection superheater, namely as an increasing function with load on the unit. It has been found, however, that the condenser type attemperator has a sensitivit'y and-duty factor which must be taken into account. The sensitivity of the condenser is not always the same at different rates of operation. With a total low of 650,000 lb. per hr. to the unit there will be some relationship between the proportioning valves which will be most satisfactory. `At a lower flow to thel unit, say 500,000

'vlb.`:"per' hrl, this same relationship between the two'valvc :openings might not give the best result due to thermal inertia and other operational eects uponthe condenser, tofsaynothingof valve characteristics, feed water pump pressure, etc.

Furthermore, sensitivity and response may vary the `requirennentsunder different conditions of cleanlins'slaiid .13a-eas 54 with different fuels being burned. Depending upon the dirtiness of the boiler and the type of fuel fired it may be possible to have zero condenser ow all the way up to 500,000 1b. per hr. and then start opening the condenser valve. Alternately, it might be necessary to start opening the condenser valve when the total ow to the boiler reaches the value of 200,000 or 300,000 lb. per hr. Thus the pick-up point of water supplied through the condenser, and sensitivity and duty demand of the condenser, may vary with cleanliness and length of operation of the unit as well as with the type of fuel fired and other operational variables, and a proper control system must be soV adapted to the unit as to result in the production of optimum final steam temperature over a wide upper range of ratings irrespective of variables encountered in the operation of the unit.

Problems encountered in the operation andl control of this type of unit may be enumerated;

l. Thermal inertia or lag of the attemperator 3 between change in the position of valve Y and resulting temperature change sensed at meter 13.

2. Change in sensitivity and duty of the condenser with dirtiness of the unit as well as type of fuel burned and other operational variables.

3. Stand-by, start-up, and similar low load operation, below the normal temperature control range, as well as in bringing the steam temperature up to desired standard without overshoot. Wide swinging loads within the controllable range of unit operatio In general these control problems are satisfactorily solved by our invention, as:

l. The air ow (demand) or (steam ow meter 100A Fig. 1A) index is necessary, due to thermal inertia or metal lag of the unit, to anticipate the effect upon final steam temperature of rapid and material load changes. However, this primary or coarse control etect is made inelective at loads normally below the control range. When load is suiciently high that the convection superheater characteristic brings steam temperature into the control range, and thereabove, the air ow anticipating eiect is available, but only during change in demand (air v ow), the impulse wiping-out on a time basis as demand steadies out.

2. The secondary, or vernier, control effect from final steam temperature, is normally effective through a proportional relay having reset action preventing stabilization at other than standard, and accelerated in its effect upon the water control valves. Below control range-the reset action is nullied and the relay eiect is multiplied in accordance with rate of temperature change above a minimum value.

DEFINITIONS Hereinafter, we use certain terms to mean:

Control Range for the controllable range of unit operation, i. e. operation from peak load downwardly to some steam rating below which the convection characteristic drops olf so rapidly that steam temperature is expectedly uncontrollable. In this example the controllable range of unit operation may be from 650,000 lb. per hr. down to some 200,000 lb. per hr.

Standard or desired value of nal total steam ternperature, for example, 1000 FTI'.

Regulating Range, sometimes called proportional band. The range of values of the controlled variable (temperature) which corresponds to the full operating range of the final control element, for example, complete expected throttling travel of valve Y for 970-1030 F.

Referring now to Fig. l we will explain our control system in connection with unit operation at or near rated load (within control range) and with final steam temperature within the regulating range of desired or standard temperature.

.Y Q Noriml'operation wthincontrolrange Whenever, the boiler load changes as indicated by a'V change in air ow at meter 10 (within the controllable range of the condenser 3), pilot 11 makes a proportionateV change in the loading pressure in pipe 12. Pipe 12 communicateswith the C chamberof a relay 16 and also,

through an adjustable bleed valve 17, with its B chamber.'

Relay 16 may 'be of ythetype disclosed and claimed in the patent to Gorrie Re. 21,804 and has an output (D) chatnber connected by a pipev 18 to a manual-automatic selector station 19 which maybe of the type disclosed and through a pipe 20,' upon the valve Y, and by way of reversing relay 21, selector vstation 22 and pipe 23 uponl valve X, calling fora change in condenser water flow;

This change is effected by movement of control valves' X and Y in opposite directions amounts determined by the valve positioners 24, 25 of valves X and Y respec' tively. The valve positioners 24, 25 may be of the type disclosed and claimed in the copending application of Harvard H. -Gorrie et al.l Serial No. 47,516 now Patent' No. 2,679,829 dated June l, 1954, and are provided with camadjustability insuring that incremental changes in control pressure in pipes 20, 23 will properly position thev valves regardless of variations in water pressure, ow resistance, valve characteristics, etc.

Fig..1B illustrates, to a somewhat larger seale, the

top mounting and valve positioner of valve Y. The

loading pressure in pipe 20 is subjected upon the interior ofa bellows 101 whose movable end acts upon a force beam 102 pivoted as at 103. The other end of beam` 102 is arranged to position the movable element of a pneumatic pilot 104 thereby establishing an output fluid pressure in a pipe 105 leading to one side of a diaphragm 106 for positioning the same. The diaphragm 106 is arranged to position the main valve stem 200 and its extension 201 as well as the ow controlling parts of valve Y. Movement of the valve stem is transmitted through gears or levers to angularly position a shaped cam 107. The cam is contacted by a follower rollerr carried on one end of a pivoted bell-crank 108 whose other arm carries one end of a spring 109 arranged to load the beam 102. The cam 107, bell-crank 108 and loading spring 109, provide a motion follow-up from positioning of the main valve stem 200 upon change in loading pressure within pipe 20 and bellows 101. The cam may be shaped to provide a linear relation between loading pressure in pipe 20 and movement of the main valve stem; orV any desired relation therebetween.

Such 'a positioner for dictating the movement of a con trol valve performs the function of a relay wherein the' iluid loading pressure (in pipe 20) originating at a` measuring controller is amplified, or modified, if necessary to overcome friction, pressure off-balance, viscous iluid effects, valve low characteristics, or the like, and position kthe valve in exact or desired proportion to changes in controller output pressure.

The loading pressure in pipe 12 is so subjected upon the relay 16 that its effect is passed on to valves X and Y only when air flow (demand) is changing. After each change, the effect of the loading pressure is gradually dissipated or wiped out during a time interval, the length of which depends uponthe speed and extent of the load change that has occurred.

An increase in pressure within pipe 12 is immediately Y felt within the C chamber of relay 16 and results in a proportionate increase n pressure in the D chamber until Arelay balance is attained. However, the pressure increase in pipe 12 is at the same time gradually effective within the B chamber by virtue of the hand adjustable bleed valve 17. Thus, in time, the increased pressure will be equally effective inthe B and C chambers so that the elect ofi the increase will cancel out. `The length of time during and 'Y is immediately transmitted,lproportionalto the .de-Y

pected change in steam temperature. ..'Iihislzinitialll action of the air ow responsive controlleravoids the necessity for waiting, after achangein the load 'ori the ringconditions,until thesechanges'have actuallyproduced alsteam i mand change, in the properdirectiontolanticipatef.theex-` temperature change before changingithe water. ilovvrate.-

ItV compensates -for the ..thermal.inertial offthev system. The change -in control pressure. is thenwiped-out on a time basis until, when `demand steadiesjthe air ilow effect isnllied. t .o l

lillof this time a. shut-oivalve';26,'in a branch 27 .of pipe-12, leadingto the VB chamber' of relay 16, is .closed off. The use of this connection will bev explained later.

,The 'eect of the loading pressurefchanges madeV in pipe 18 by the air flow responsive .controller10 is continually checked, corrected and/orV replaced by changes inthe loading pressure originatingifrom the final steam temperature controller 13, in pipelS. This acts through a `standardizing relay .28 andy an'k accelerating relayw29, upon the A chamber of relayl, to. determinethenal accurate; adjustment of the water ilow'to the condenser, to maintainthe steam temperatureldesired.

`lressure .within .thepipe is subjected upon theLA chamber of the `relay 28 which may be of theV standlardizing type disclosed and claimed in the Gorrie Patent Re. 21,804. ,The relay is provided with an adjustable bleed connection 30 interconnecting the D and C chambers .so that there is a continual tendency to equalize the 'pressures in these two chambers. The resulting reset action prevents-stabilizing out at a steam temperature otherthan standard The output loading pressure Aof the D chamber is introduced into the A chamber of an accelerating relay 29 which may be yof Ythe type disclosed and'claimed inthe patent to Fitch 2,441,405.

. The relay 28 provides a proportional control with reset characteristics. It provides for the Vernier control index (final steam temperature) alloating control of high sensitivity"superimposed upon a positioning control: of relativelylow sensitivity. The function'of the adjustable bleed'conne'ction '30 is to' supplement l the`pr in'ary control 'offthe pressure etiective'in the output pipe v31v withV aise'c'ondary conti-'ol 'of the same 01""di`fferent',magnitudeas' a"followupjor` supplemental action. The sensitivityof thecontroller1?` may be adjusted to provide a proportional band ofgsay 301:. each side of ,standardv (1000 FTT)so thatwerefthe relay 28 functioning as a simple proportional response type, the output pressure v in pipe 31 wouldfbe varied between the. limitsS-ZS p.V s. i. fortemperature migrationsof 970-41030 F. However, such a system might tend to stabilizeV out at temperatures above or below the desired standard.k The reset action provided in the relay tends always to return steam temperatureto the desired standard with a minimum 'of over-travel or hunting.

In normal operationv then, within the controllable range of'loads upon the unit, and' with steamy temperature within the selected regulating range across the standard temperature, departure of temperature from standard varies the loading pressure in pipe 1S' and, acting through the` standardizing relay `28 Vand accelerating relay 29, is

effective lin the 'A chamber of reljay/ 16 to algebraicajlly combine'itsjeiect with any pressfu're velect' frftfni zairflow in 'relay 16,A and act to position water valvesX andpY.

iro

A11 or this' timetne valve 32er the entrance tdthe C L chamber 'ofrelayZS is'closed. Y

n Operation outsal of control rfa-ngt; `VThe unit'tofathefpresent example :is iassumed to.. have aratedgcapacityof.500,000 1b. perrhr; and 650,000 1b.V per hnpeakpperation, -atl200 p..s.,i. g. and 10.00 .The controllable? range. of. operation mayxbe, `for. example, fron120000,0, to .650,000 lb.,per. hr. Below/200,000 the convection -superheater vcharacteristic curve .may preclude anypossib,iltiy ,of maintaining steam temperatureacontrollably near. the .des-ined. standard l and `final ,steam vvtemperature may fall off rapidly with rafting. vProhlemsattendent stand-by, start-,up for'simlar low load .operationv below the controllable., range, or ,onwidely t swinging loads which may carry the steamtemperature temporarily outside .the selected` regulating range, 'have produced .a1dditional featuresrin the'systern ofFig. l, of `our invention, and which will now be described. ,i

v With a proportional -type relay (.28).having Lresetclzlaracteristics it `is known that asthe temperature returns to fthecontrolfpoi-nt or standard,g the regulatinglrange shifts. It is this shifting of the range which restores the temperature to standard after a load change. Therefore, by the Eaddition of .automatic'reseh the standard is maintained undernormall'oad conditions,- but start-,up characteristics may become poor. This possibility,'with a relay such as 28,*is known as `bleeding-out-of-range. j.

The spring load-ingofprelay 28 is normally about l5 p. s. i.( rnidwayof `2 5Yregulating'range). Whenvthe temperature ,is at standarmrthe, pressure in, A chamber balances the spring loading and the supply-exhaust valves *Ofsfhe'D shamber are in .a neutral. Position. holding a constant pressure (any value'within the range 545 p. s, i.) in the D'and C eharnbers.., Sincel they temperature isat standarda steady state prevails,4but the pressure. inD

may, onrnaynot, be the Vsame as in A lf temperature,l departs fromustandard thecontroller will transmita new proportional pressure to A chamber, and the balance between A pressure and spring loading will be upset. lWhen the systemagain balancesjout the pressure in D chamber' may be at an entirely new. value.

Isuclicase' 'no' change'incontrol pressure and'no` effective movementof the water valves willV result from approach of steam temperature toward standard until it has actually arrived 4there, and the steam temperature arrives at standard value with the Water valves at one extreme or the other. .The result may be a severe yovershoot before the system steadiesout. v i

By way of example, assume thatthe unit has beenon stand-by (below 200,000 lb; perhr.) or perhaps, maintaining pressure without vapor outflow. Vapor koutflow begins at saturation temperature and, dueto the characteristics ofthe convection superheatcr, there must be la subs stantial rating attained before iinal steam temperature approaches the regulating range (97,0-1030 F.) Allof this time the control pressurein' pipe 31 has'been out-ofrange. As previously pointed out, fthe steam temperature mayconsiderably over-shoot before the system settles out. Wide and sudden swings of rating during otherwise normal operation withinthe controllable range may result in the same over-shooting j .A .preferred way :ofV obviating ythis overfshooti'ng. is to remove ,the standa'rdizingv or y reset action from lthe relay 28 upon, startup v enduring any `operation outside of the controllable ragseof-opsrai0asr at .enviame when, steam Jempe'rature is withoufthe lselected regulating-tangent araches' effect is admitted to the C chamber of relay 28 by way lof pipe 35. Thus, with valve 32 closed, relay 28 functions as a standardizing relay with reset characteristics, asv

previously explained. When steam temperature is below 970 F., as `on start-up or wide range swings, the valve 32 is open and pipe 35 subjects Iupon the C chamber of Y relay 28 the output pressure of the D chamber of a multiplying relay 36.

Pipe 15 connects :directly to the A chamber of relayl 36 and to the lB chamber by way of a hand adjustable bleed valve 37. Thus the output of relay 36, available in pipe 35, is varied only upon change in steam tempera ture; any change in A chamber loading being slowly wiped out as the pressure change bleeds through valve 37 'to equalize the A' and B chamber pressures.

It will be seen that, with valve 32 open, the action of p relay 28 is doubled, or multiplied by some amount less than twice its A chamber pnessure, i. e. the A and C` chambers act in the same direction. Therefore, during` start up or under widely swinging loads, the reset `action of relay 28 is replaced by an eiect which is a multiple of lits A chamber loading.

When below, but approaching control range, condenser water ow anticipation isdesirable, particularly if temperature is rising rapidly, in order to prevent over-shooting the desired temperature. Therefore, below 'the control range, valve 32 is fopen, connecting pipe 35 to the C' chamber of relay 28. This changes the standardizing action of the relay 28 into a multiplying action fromi the temperature controller 13. The extent to whichV impulses from controller 13 are increased depends upon the speed and extent of steam temperature change, due

to the adjustable bleed valve 37 which dissipates `the effect l -40 In addition, the spring loading on relay 36 is such as to produce an output fof approximately 7 p. s. i. when the relay is in equilibrium. Thus, even when the A and B .of -this relay at a rate proportional to the initial change.

chambers of relay 36 are in equilibrium, there is an effective pressure of 7 p. s. i. (slightly less than one-half C chamber of relay 28 when the valve 32 is fopen.

As the boilerload rises, the doubling or multiplying:

action of these relays calls for a condenser flowl even before 'the desired steam temperature is attained. A rapid standardizing and reset action.

This would convert relay 28 into a true doubling relay.

The trouble with applying the pipe 15 loading pressure directly into the C chamber of relay 28, rather than going through the relay 36 is that it could, acting as a temperature are transmitted through tothe C chamber `70 the pipe 15 pressure slowly into p of the standardizing relay 28 and then this impulseis wiped out by bleeding the B chamber of the relay 36. Thevlaster' the steam of the 5-25 p. s. i. possibility) always effective upon the V temperature rise calls for more condenser flow than an equal slow rise. When the temperature rises to 970 F.

(or some other selected limit below the standard value) 'r the bellows 32 closes, restoring relay 28 to tits normali The question will arise as to why pipe 15 pressure is not admitted directly to pipe 35 and relay 36.0mitted.

temperature increases, coming up'to the point at which the shut-off valve 32 trips, the further open it carries l the condenser inlet valve, since the wipe-out eect of relay 36 would have Ylittle time to malte itself felt. vii

the temperature increased at a slower rate than' the rate of wipe-out in theY relay 36, it would just put the standardizing relay 28 back in :action with 5 p. s.. i. .loading out of its D charnben'which would be the correct thing to do, since the slowly increasing temperature can be handled satisfactorily lby the 4regular control action without any anticipating help or doubling or multiplying action. This is because it would not have to wait for the standardizing relay 28 to build up from say 0 to 5 p. s. i. that had previously bled out of range.

While loading the C'chamber of the relay 28 prevents., it from bleeding out of range; the use of the relay 36 is'l primarily'additionally for the purpose of getting the condenser valve open before the temperature reaches standard after operating below the standard period of time. The relay 36, or the merely nullifying the standardizing or reset action. With the invention of Fig. l we attain the doubling or multiplying eiect well up into the range of operation and go back into the reset action when the temperature has almost reached standard. There is an advantage to this v because on a load pick-up there is a certain amount of over-tiring of the unit to maintain steam pressure and to initiate superheating of the saturated steam, and this doubling or multiplying action of the relay 28 actually produces an over-control action to effect of the over-firing.

GENERAL During normal operation, within the controllable 'I range of the unit, and with final steam temperature within the selected regulating range, an anticipating effect is available from changes in demand (air flow) slowly Variations.

wiped out on a time basis as demand steadies. in steam temperature from standard act through a standardi'zing relay having reset characteristics; and through an accelerating relay, upon an averaging relay Where the eiect is algebraically added to the air flow eiect and the resultant positions the valves X and Y.

Under start-up or widely swinging load operation, with steam temperature below the lower limit of the regulating range, demand (air flow) does not enter the picture. This is true because valve 26 is open when steam temperature is outside the'regulating range, for example below 970 F.

Opening of valve 26 imposes the loading pressure of pipe 12 upon the B chamber of relay 16 thus making the B start-up, stand-by and other conditions of operation not normally handled by known control systems.

In connection with Fig. 1 we have spoken of positioning the valves X and Y, through the agency of reversing relay 21, to move the valves relatively in opposite directions for proportionng the water between the economizer and the condenser. Under certain conditions of design and operation it vmay be desirable to open both valves X and Y at the same time but possibly at different rates.

Operation I Under the arrangement of Fig. 1, where valve Y may be opening while valve-X is closing, it will be understood that the total supply of feed water to the unit is controlled innormal manner either by control of the feed pump or of a master supply control valve in ow under such regulation,

fixed lowV value continually for an appreciable doubling action on the standardizing relay 28, is lfound to be better than somewhat offset the A the pipes ahead of the proportionng valves X, Y. With theft'o'tal i; the valves X, Y proportion l, the total through the economizer and condenser, over the admitted to the economizer.v through the valve 9 to prevent any possibility of steanirig.`

I-his iixedfvalue may, for example,be at a rate of 10,000`

lb.` per hr. for the unit under consideration. l

",As one example of operationin Aaccordancewitl'i Fig. l, the'total water supply through 'the pipe 5 may increase substantially linearly with rating from to 500,000 lb. per hr. rate. 'The condenser valve Y may be closed and not start tolopen until an output rate of some 200,000 lb. per hr. The economizer valve X may be wide open until'some rating of say 300,000 1b. per hr.y After the condenser valve Y and the economizer valve X each begin to move they may move at different rates, the one from the other, and in opposite direction, `the vvalve Y opening while the valve X pinches'down so that water is fdiverted from the economizer through! the condenser. yIt will be lappreciated that limit stops, air loading, spring loading, adjustment of the valve positioners 24, 25, etc. provide' for the pick-up .pointof the two valves as well as the' 'slope of their opening'and/or closing relative to eachother.

Operation 2 Under certain design conditions ofpipe sizing, valve sizing with'reference to'economizer and condenser pressure drops, as well as pressure drop conditions and characteristics of the main control valves and/or feed pumps, it may be desirable to take Va part of the total pressure drop through the valves X vand Y and have them both open at the same time but possibly at different rates. For example it may bedesirable to have the condenser valve closed up to say 300,000 lb. per hr. rating and to have the economizer valve X say one-half closed upto-some 350,000 lb. per hr. rating. At the indicated ratings the valves would begin to open and open at predesigned rates which may be dilferent the one from the other. Presumably under this operation the economizer valve would open at a faster rate than the condenser valve. j

It will be appreciated that either type of operation may be accomplished by the adjustment of the yvarious pieces of apparatus diagrammatically indicated in Fig. l.

VReferring now particularlyto Fig. 2 We indicate thereon additional operational and control features over that justdescribed in connection with Fig. l. YSimilar parts bear the same reference numerals. l

In` Fig. 2` an additional operational index-is utilized in the control, namely the measured rate of flowof-water supplied through the pipe 7 to the condenser.Y Water flow meter-40 is connected to be sensitive to the rpressure differential existing across an orice 41 locatedinthe pipe 7 and positions the movable element of. a pilot 42 toprovide in a pipe 43 a pneumatic loading pressure continuously representative of rate of ilow of water tothe condenser 3. This provides a-measured water ow checkbaclr..against the `water supply demand originated` (as previously described in connectionwith Figs. 1 and 1A) by the air ilow, steam flow, or demand index andthe final steam temperature index.

In lorder to obtain adjustment llexibility, characterizers 44 and 45 are included in the loading pressure. lines 43 and 12 lrespectively from the water ow and air flow respon-l sive controllers 40 and 10. By means of these, thev elective loading pressures from the controllersmay be given desired linear or non-linear characteristics to suit the characteristics of the equipment under control. Such characterizers may be of the type disclosed and claimed in the patent to George E. Luppold, Jr. No. 2,777,457.

Characterizers permity the relative sensitivity` depending upon load for the air flow anticipation andsince wemay not have uniform elliciency on the condenser ilow,it is desirable there also. In other words, assuming a Ycertain maximum vduty and'correspondingcondensingwater tlow, iftheduty lisjhalijlas much we are not.y sure if the`.water owshould be half as much becausethefeiciencyiof the condenser may V,not be' uniform C at 'all loadsifffhe' con.- denser l-duty is related'toboiler load and. excess air and is thereforel normally relatedto air. orfgas tlow throughthe boiler. However, the relationship varies with the type of fuel and-also with boiler cleanliness. For that reason 4the air flow element is used for anticipation only and its effect felt only on a change in air, neutralizing out when air flow steadies. In order to give proper sensitivity regardlessof rating, the air loading produced by air tlow measurement is characterized and equipped with a cam making possible small increment loading changesv on given air ilow changes at low loads and larger loading changes for equal air tlow changes at high loads.

Fig. .2A illustratesA the characterizer 45 to a larger scale. The loading pressure of pipe 12` is effective within a bellows which exerts a force upon beam 111.. Beam 111 positions. the movable element of a pneumatic pilot valve 112 establishing an output control pressure in pipe 27. Opposing the force of bellows 110, upon beam 111, is a spring 113 loaded by a bell-crank 114.l The bellcrank is positioned by a cam 115, in' turn positioned by a diaphragm 116 through the agency of a member 202-203, in response to pressure in pipe 27.

Thus, the characterizer 45 is inserted between the loading pressure of pipe 12 and the output pressure of pipe 27, to-characterize or change the pressurel signal in accordance with the shape of the cam 115. If the cam is a vlinear rise type then pressure in 27 is directly proportional to pressure in pipe 12. Preferably, the cam is shaped when the system is calibrated or tuned-up and may take into account operational characteristics of the fans and other plant equipment.

By tying condenser water ow into the picture 'it is not essential to have definite port shapes in the control valves and these valves will necessarily position themselves to produce the required condenserr ow as called for by the condenser duty indicated by air loading from the relay.

The arrangement of` Fig. 2 follows the Operation 2 previously discussed with the possibility of the valves X and Y opening in parallel but perhaps atdiierent rates. It will be seen that the reversing relay 21 of Fig. 1 has been omitted in Fig.'2 so that the air loading pressure in the pipes 20, 23 act in the same direction upon the valves X and Y.

In the arrangement of Figsl we have shown only the steam temperature impulse accelerated because, dueto .change-alone to remove this'over-shoot, we have'waited too longand will'have an unstable control. 'For this reason accelerating relay 29 is eiective` only on the steam temperature impulse. It is of course Yquite possible that, under some conditions of design 'or operation, we would wish to accelerateboth the steam 'temperature and air ilow"(den"iand) impulses, or the resultant of all of the impulses, or Awe might wish to accelerate the steam temperature lat'one rate 'and' the airow at'an'other rate. By waylof example, we show in 'FigL`2 v'that the acceleration is of the steam temperature and air' flow, while in Fig. 3 'we 'show the resultant of the steam temperature and the 'drum'level-accelerated. V

Thebellows operated shut-off valves 32, '26 of iFig. l are replaced Fig. 2 by solenoid actuated valves 32A fand' '26A, electrically actuated 'from the` steam temperature controller 13. Contacts 46 4areprovided in the controller" 13'; one-set for operation of solenoid` valve 32A. and,Y the'othe'r' settor operation of solenid valve 26A.' .djus'tmentofthesecontacts allows the possibility ofjrop'eni-ngorfclosing valvesfZ6A .and 32A at different values",'igsteamA temperature andj with an adjustable amountf'overlp 'or' gap between the steam temperaturejvalue of opening orjclosing each of the valves.

, This precludes vany"j aossibility of huntingback and'forth might seriously disturb the control across a particular temperature value at which the shutoff valves might open or close if thersame value were used for opening as for closing. `In other words, in coming up on steam temperature valves 26A, 32A may close at a temperature of sa'y 970 F. while the valves may not open until the steam temperature has fallen to a value of 965 F.

In thewiring 47, from the contacts 46 to the valve 26A, we provide a disconnect switch 48 which may be hand actuated at times of blowing soot from the heat exchange surfaces of the unit.V This provides a possibility of shorting in parallel with the proper contact 46 to open the valve 26A and remove-air tiow impulse from the system during time of air flow disturbance by soot blowing. During such soot blowing period the system will remain on automatic but operates from steam temperature impulse and water flow meter impulse only. Without this possibility the wide disturbing inuence of blowing soot, upon air ow rate through the unit, system presently being described. v

Fig. 2B is a more detailed diagram of the electric wiring of Figs. 2 and 3. The solenoid actuated valves 26A and 32A are shown in very diagrammatic manner, each having an opening and a closing winding. Within the measuring controller 13 a member 120 is positioned longitudinally in accordance with steam temperature value. Carried by the member 120 are two contact actuators 121, 122, separately adjustable along the member to desired temperature values, and arranged to energize the proper circuits for opening, or closing, valve 26A and/or valve 32A at predetermined temperature values.

In general the arrangement of Fig. 2 provides, during normal operation, that the relay 16 passes to the pipe 18 an air loading pressure resulting from the steam temperature controller 13. This output pressure in the pipe 18 is subjected upon the A chamber of a differential standardizing relay 50, to the B chamber of which is subjected the loading pressure from the pipe 51 output of the water ow controller 40. The output of the differential standardizing relay 50, available in the pipe 52, joins the manual-automatic selector station 19 and the control pipes 20, 23. Positioned in the pipe 23 is a similar manual-automatic selector station 22 so that the stations 19, 22 allow the possibility of hand positioning of the valves X and Y.

The arrangement of Fig. 3 is directed to a unit of somewhat larger size and different arrangement. For example, this system is arranged to control final steam temperature on a unit having normal operating capacity of 1,200,000 lb. per hr. with peak capacity of 1,450,000

lb. per hr., at 1850 p. s. i. g. and 1000 FTT, with a reheat section producing steam at a final temperature of 1000 FTT. It is expected that the controllable range of final steam temperature is 500,000 to 1,450,000 lb. per hr. operation. The particular arrangement of Fig. 3 is in connection with control of the temperature of steam heated through serially connected primary and secondary superheaters with the condenser attemperator 3 located therebetween. The reheat surface is subjected to heated gases proportioned thereover by a control of series and by-pass dampers conjointly from an index of demand (air ow) and final reheat steam temperature. Such control is not new and is therefore not included in the present Fig. 3.

I-n this arrangement the control is primarily a three-element control with the primary control from the air flow index giving anticipating eects as previously outlined.

The temperature of the steam leaving the tinal or secondary superheater, as well as the measured rate of ow of water to the condenser, are used as secondary controllers. However, a fourth element, drum level, is incorporated in this control system to prevent flooding of the boiler drum in the event that a condition should l boiler drum because condenser` water liow is takenl off of the-main feed water-header aheadv ofl-the feed water control-valve. Y A

Steam from the drum 1 passes serially through a primary superheater 4, an attemperator 3, and a secondary superheater 60. Final steam temperature at the outlet of the secondary superheater 60, namely at location 61,` is the activating index fora controller 13.- Total feed water supplied to the boiler drum enters the unit through the conduit 5 and is regulated in well known manner from a three-element controlutilizing the indexes total Y steam outflow rate across an orifice 62, total water inflow rate across an orifice 63, and level in the drum 1,

to conjointly be effective in positioning the total regulating valve 64 at .the entrance to the economizer 8. It will be seen that, while the three-element vregulating system is responsive to total water supply rate, the valve 64 p does not include a regulation of the water passing through the pipe 7 and attemperator 3 which is diverted from the pipe 5 between the orifice 63 and the regulating valve 64. To preclude any possibility of `atight closed valve 64 starving the economizer 8, it may be desirable to return the condenser water through a pipe 65 to the entrance of the economizer 8. Thus, there will at all times be a minimum of say 5000 or 10,000 lb. per hr. water passing through the economizer to prevent it from burning out even though valve 64 is tight close Level within the-drum 1 is yused as an element in the control system of Fig. 3 to check-back on-actual drum level and prevent flooding the drum'in the event of a condition which mightexist where the valve 64 is completely closed and still the control system'called for a supply of water through the valve Y, conduit 7, attempery ator 3, pipe`65 and economizer 8. Thus a inal checkback on the level of water within the drum 1,. sensed by a meter 67, positions the movable element'of a pilot 68 to provide a fluid loading pressure in the pipe 69 continuously representativerof drum level. The adjustability and sensitivity of the controller 67 is such that the effect of the loading pressure within the pipe 69 acts in the B chamber of differential standardizing relay 28A only if dangerous dru`m level is approached. Otherwise the system of Fig. 3 is similar to that previously described in connection with Fig. 2 except that the total control is by the valve Y. y

While we have chosen to illustrate and describe certain preferred embodiments of our invention, it will be understood that this is by way of example only and not to be considered as limiting.

What we clairn as new, and desire to secure by Letters Patent of the United States, is: j

l. The method of controlling the nal'temperature of superheated vapor leaving a vapor -generating-unit, which includes, passing the vapor under pressure serially from a separation drum through an indirect contact heat exchanger and a superheater, supplying one portion of liquid to the heat exchanger for heat exchange with the vapor passing therethrough and hence to the separation lable range of demand and with vapor temperature within a selected regulating range jointly utilizing the measurement and the demand index to control the proportioning of liquid feed as between the portion which first passes through the heat exchanger and that portion which goes directly to the drum, and during subnormal operax tion below the controllable range or below the selected regulating range utilizing onlyfthe measurement of vapor temperature but on a magnified basis to effect the proportioning.

avantage 21. The combination of claim 2O including measuring means for establishing a control signal or effect continuously representative of the superheated vapor nal temperature arranged to impress said control signal or effect on the second means to assist in actuating the regulating means throughout said preselected range of ratings and, wherein the measuring means is arranged to solely actuate the regulating means through ratings outside said preselected range.

22. Apparatus for controlling the operation of a vapor superheating unit within a preselected range of total rating operation of the unit including in combination, means regulating the nal temperature of the superheated vapor in sense or direction tending to return the temperature toward an optimum value upon a departure therefrom, demand responsive means immediately effective upon change in demand within the preselected range of ratings and adapted to actuate the regulating means, delayed action means for the demand responsive means gradually making such means ineffective when demand steadies, measuring means for the superheated vapor final temperature arranged to assist in actuating the regulating means throughout said preselected range of ratings, the measuring means being arranged to solely actuate the regulating means through ratings outside said preselected range, and multiplying means for the elect of said measuring means in actuating the regulating means when the measuring means is solely actuating the regulating means.

23. The method of controlling the final temperature of superheated vapor leaving a vapor generating and superheating unit, which includes, passing vapor under pressure serially from a liquid-vapor separation drum through a first superheater contacted by heating gases then through a heat exchanger of the indirect type and finally through a second superheater contacted by heating gases, supplying heated liquid under elevated pressure to the unit for producing vapor to to be superheated, passing a proportionate flow of the liquid through the heat exchanger on its way to the vaporizng portion of the unit, measuring the final temperature of the superheated vapor, obtaining a measurement of the index of demand for superheated vapor upon the unit, measuring the rate of flow of liquid passed through the heat exchanger, separately establishing a control signal or effect for the measurements of final temperature of the superheated vapor and the rate of ow of the liquid passed through the heat exchanger continuously representative of the value, conjointly utilizing the control signal or effeet representative of each of the measurements of inal temperature of the superheated vapor and of the rate of flow of liquid through the heat exchanger in controlling the rate of liquid ilow through the heat exchanger during all rates of unit operation, establishing a control signal or effect continuously representative of the index of demand, and modifying the control of the rate of liquid ilow through the heat exchanger in yaccordance with the demand control signal or effect when demand isV changing and through a preselected controllable upper range of unit ratings or above a preselected vapor temperature by gradually applying said demand control signal or eiect in opposing relation to the demand control signal or effect utilized to modify the control of the rate of liquid flow through the heat exchanger so as to nullify or wipe out the demand control signal or efect.

24. The method of claim 23 wherein the index of demand is a measurement of the rate of ilow of the heating gases contacting at least a part of the heat exchange surfaces of the unit.

References Cited in the file of this patent UNITED STATES PATENTS 2,255,612 Dickey Sept. 9, 1941 2,319,223 Frisch May 18, 1943 2,416,261 Kemper Feb. 18, 1947 2,526,843 Birchler et al. Oct. 24, 1950 2,526,898 Powell et al. Oct. 24, 1950 2,575,885 Mittendorf Nov. 20, 1951 2,580,345 Dickey Dec. 25, 1951 

